Automotive Technician Training: Practical Worksheets Level 2
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Automotive TechnicianTraining:Practical Worksheets Level 2Automotive practical worksheets for students atLevel 2This Level 2 student worksheets book contains tasks that help you developpractical skills and prepare you for assessment. The tasks also reinforce theautomotive theory that you will learn online and in the classroom. Eachworksheet covers individual topics in a step-by-step manner, detailing how tocarry out all the most important tasks contained within the syllabus.Alongside each of these worksheets is a job card that can be filled in and usedas evidence towards your qualification.Endorsed by the Institute of the Motor Industry for all their Level 2automotive courses.Step-by-step guides to the practical tasks required for all Level 2qualifications.Job sheets for students to complete and feedback sheets for assessors tocomplete.Tom Denton is the leading UK automotive author with a teaching careerspanning lecturer to head of automotive engineering in a large college. Hisrange of automotive textbooks published since 1995 are bestsellers and led tohis authoring of the Automotive Technician Training multimedia system thatis in common use in the UK, USA and several other countries. Tom now worksas the eLearning Development Manager for the Institute of the Motor Industry(IMI).www.FreeEngineeringbooksPdf.com
Automotive TechnicianTrainingPractical Worksheets Level 2Tom Dentonwww.FreeEngineeringbooksPdf.com
First published 2015by Routledge2 Park Square, Milton Park, Abingdon, Oxon OX14 4RNand by Routledge711 Third Avenue, New York, NY 10017Routledge is an imprint of the Taylor & Francis Group, an informa business 2015 Tom DentonThe right of Tom Denton to be identified as author of this work has been asserted by him in accordancewith sections 77 and 78 of the Copyright, Designs and Patents Act 1988.All rights reserved. The purchase of this copyrighted material confers the right on the purchasinginstitution to photocopy pages which bear the copyright line at the bottom of the page. No other parts ofthis book may be reprinted or reproduced or utilised in any form or by any electronic, mechanical, orother means, now known or hereafter invented, including photocopying and recording, or in anyinformation storage or retrieval system, without permission in writing from the publishers.Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are usedonly for identification and explanation without intent to infringe.British Library Cataloguing-in-Publication DataA catalogue record for this book is available from the British LibraryLibrary of Congress Cataloging in Publication DataA catalog record for this book has been requestedISBN: 978-1-138-85237-2 (pbk)ISBN: 978-1-315-72351-8 (ebk)Typeset in Univers byServis Filmsetting Ltd, Stockport, Cheshirewww.FreeEngineeringbooksPdf.com
ContentsPractical Worksheets – Level eeringbooksPdf.com
Practical Worksheets – Level 2IntroductionThe purpose of this worksheets book is to provide a range of practicalactivities that will enable you to develop your abilities as a technician. Thetasks are aligned with recognized vocational qualifications. However, there arefar more tasks within this workbook than are required by the awarding bodyfor the achievement of a Vocationally Recognized Qualification – because themore you practise, the more skills you will develop.The worksheets are presented as three separate books at Level 1, Level 2 andLevel 3 to follow the recognized qualifications. Within each level there aretasks for the major automotive areas: Engines, Chassis, Transmission andElectrical. The tasks range from component identification to removal and refitat Level 1 and 2, and diagnosis of complex system faults at Level 3.A blank job card and assessor report are provided with each worksheet. Thisshould be copied and then filled in alongside the task you are completing,including all relevant details regarding the vehicle, the fault and therectification procedure where appropriate. You should write down adescription of the work that you did to complete the task including anytechnical data that you sourced, any difficulties that you encountered and howyou overcame them. If you had any health and safety issues to address, i.e.disposal of waste materials or clearing up spillages, this will help demonstrateyour competence. By completing job cards thoroughly at this stage of yourcareer as a technician, you will be well prepared for the time when you arerequired to complete job cards in the workplace. This can be very important,for example, if a warranty job card is not accurate then the manufacturer willnot pay for the claim. An example of a completed job card is shown on page 7.For teacher/lecturers, this work book more than covers the requirements forVocational Qualifications. Using the following tracking document you cannote progress and also cross-reference the highlighted worksheets that directlyrelate to the awarding body required practical tasks.Trackingwww.FreeEngineeringbooksPdf.com
Important notes about practical workSafetyWorking on vehicles is perfectly safe as long as you follow proper procedures.For all of the worksheets in this book you must therefore:Comply with personal and environmental safety practices associatedwith clothing; eye protection; hand tools; power equipment; properventilation; and the handling, storage, and disposal ofchemicals/materials in accordance with all appropriate safety andenvironmental regulations.There are some specific recommendations below but you should also refer tothe other textbooks or online resources for additional information.Personal protective equipment (PPE), such as safety clothing, is veryimportant to protect yourself. Some people think it clever or tough not to useprotection. They are very sad and will die or be injured long before you! Somethings are obvious, such as when holding a hot or sharp exhaust you wouldlikely be burnt or cut! Other things such as breathing in brake dust, or workingin a noisy area, do not produce immediately noticeable effects but could affectyou later in life.www.FreeEngineeringbooksPdf.com
Eye protection and gloves in useFortunately the risks to workers are now quite well understood and we canprotect ourselves before it is too late. In the following table, I have listed anumber of items classed as PPE (personal protective equipment) together withsuggested uses. You will see that the use of most items is plain common sense.Equipment NotesSuggested or examples where usedEardefendersMust meet appropriate standardsWhen working in noisy areas or if using an airchiselFace maskFor individual personal use onlyDusty conditions. When cleaning brakes or ifpreparing bodyworkHighvisibilityclothingFluorescent colours such as yellow ororangeWorking in traffic such as when on a breakdownLeatherapronShould be replaced if it is holed or wornthinWhen welding or working with very hot itemsLeatherglovesShould be replaced when they becomeholed or worn thinWhen welding or working with very hot items andalso if handling sharp metalworkwww.FreeEngineeringbooksPdf.com
Life jacketMust meet current standardsUse when attending vehicle breakdowns on ferries!OverallsShould be kept clean and be flame proof ifused for weldingThese should be worn at all times to protect yourclothes and skin. If you get too hot just wear shortsand a T-shirt underneathRubber orplasticapronReplace if holedUse if you do a lot of work with battery acid orwith strong solventsRubber orplasticglovesReplace if holedGloves must always be used when usingdegreasing equipmentSafetyshoes orbootsStrong toe caps are recommendedWorking in any workshop with heavy equipmentSafetygogglesKeep the lenses clean and preventscratchesAlways use goggles when grinding or when anyrisk of eye contamination. Cheap plastic gogglesare much easier to come by than new eyesSafetyhelmetMust be to current standardsUnder vehicle work in some casesWeldinggoggles orweldingmaskCheck the goggles are suitable for the type You should wear welding goggles or use a maskof welding. Gas welding goggles are NOT even if you are only assisting by holdinggood enough when arc weldingsomethingAlso, as well as your own protection you should always use a protection kitfor the vehicle: floor mats, wing covers and seat covers for example.Tools and equipmentTo carry out any work you will need a standard toolkit and in some casesadditional ‘special’ tools will be required. Make sure you have access to allnecessary equipment before starting work. A few examples are mentionedbelow but you should also refer to the other textbooks or online resources foradditional information.Using hand tools is something you will learn by experience, but an importantfirst step is to understand the purpose of the common types. This sectiontherefore starts by listing some of the more popular tools, with examples oftheir use, and ends with some general advice and instructions.www.FreeEngineeringbooksPdf.com
ToolkitPractise until you understand the use and purpose of the following tools whenworking on vehicles.Hand toolExample uses and/or notesAdjustablespanner(wrench)An ideal stand by tool and useful for holding one end of a nut and bolt.Open-endedspannerUse for nuts and bolts where access is limited or a ring spanner can’t be used.Ring spannerThe best tool for holding hexagon bolts or nuts. If fitted correctly it will not slip anddamage both you and the bolt head.Torque wrenchEssential for correct tightening of fixings. The wrench can be set in most cases to ‘click’when the required torque has been reached. Many fitters think it is clever not to use atorque wrench. Good technicians realize the benefits.Socket wrenchOften contain a ratchet to make operation far easier.Hexagon socketspannerSockets are ideal for many jobs where a spanner can’t be used. In many cases a socket isquicker and easier than a spanner. Extensions and swivel joints are also available to helpreach that awkward bolt.www.FreeEngineeringbooksPdf.com
Air wrenchThese are often referred to as wheel guns. Air-driven tools are great for speeding up yourwork but it is easy to damage components because an air wrench is very powerful. Onlyspecial, extra strong, high-quality sockets should be used.Blade(engineer’s)screwdriverSimple common screw heads. Use the correct size!Pozidrive,Philips andcrossheadscrewdriversBetter grip is possible particularly with the Pozidrive but learn not to confuse the two verysimilar types. The wrong type will slip and damage will occur.Torx Similar to a hexagon tool like an Allen key but with further flutes cut in the side. It cantransmit good torque.Special purposewrenchesMany different types are available. As an example mole grips are very useful tools as theyhold like pliers but can lock in position.PliersThese are used for gripping and pulling or bending. They are available in a wide variety ofsizes. These range from snipe nose, for electrical work, to engineers pliers for larger jobssuch as fitting split pins.LeversUsed to apply a very large force to a small area. If you remember this you will realize how,if incorrectly applied, it is easy to damage a component.HammerAnybody can hit something with a hammer, but exactly how hard and where is a greatskill to learn!General advice and instructions for the use of hand tools (taken frominformation provided by Snap-on):Only use a tool for its intended purposeAlways use the correct size tool for the job you are doingPull a spanner or wrench rather than pushing whenever possibleDo not use a file or similar without a handleKeep all tools clean and replace them in a suitable box or cabinetDo not use a screwdriver as a pry barLook after your tools and they will look after you!InformationBefore starting work you should always make sure you have the correctwww.FreeEngineeringbooksPdf.com
information to hand. This can be in the form of a workshop manual or acomputer-based source.The worksheets in this book are a general guide so make sure thecorrect information, procedures and data for the particular vehicle youare working on are available before you start work.Autodata online informationwww.FreeEngineeringbooksPdf.com
Job card: exampleAssessor report: examplewww.FreeEngineeringbooksPdf.com
EnginesWorksheet 1: Routine vehicle maintenanceinspections/serviceProcedureGeneral visual inspection – listen for abnormal noises.Visual/oil level and condition. Replace oil and filter at specified intervals.Visual/inspections for oil leakage.Visual/inspection of exhaust smoke – at idle speed at mid-engine speed (3000rpm) on overrun during road test.Engine oil pressure test – check warning light operates (attach a pressuregauge and adapter and tachometer) – pressure at idle speed – stabilizedpressure – stabilized pressure engine rpm.Crankcase ventilation system – check condition of hoses (visual and removehoses and valves) – orifice to inlet manifold clear – air cleaner condition –control valve condition.Check coolant level and specific gravity.Check brake operation and pad/disc condition – record thickness.Check tyre tread depths.Torque wheel nuts – include torque figures and calibration date of torquewrench.Additional items – see manufacturer’s schedule.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 2: Vehicle inspectionsProcedureGeneral visual inspection – listen for abnormal noises.Check brake operation and pad/disc condition – record thickness.Check tyre tread depths.Torque wheel nuts – include torque figures and calibration date of torquewrench.Additional items – see manufacturer’s schedule depending upon type ofinspection – pre- and post-work, pre-delivery inspection (PDI), prepurchase inspection (PPI), pre MOT, visual health check (VHC) or postrepair.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 3: Adjust valve clearances (OHV)ProcedureRun engine and listen for abnormal noises from top of engine. Check formisfire/cylinder balance. Disconnect battery earth/ground cable. Removerocker cover.Measure with feeler gauges all valve clearances at the ‘back-of-the-cam’(heel) position. Check manufacturer’s recommended procedure forpositioning the engine, e.g. rule of nine or valves rocking method.Adjust each valve using a special tool or wrench and screwdriver asappropriate. Note that inlet and exhaust settings may vary.Refit all and run engine to check for noise or misfire.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 4: Inspect camshaft lobes, journals andbearings, auxiliary shafts, bearings and driveProcedureStrip to access the camshaft. Check the end float before removing.Remove camshaft and visually inspect for condition of bearing journals andcam lobes. Inspect retaining/thrust plate for wear.Inspect bearings in the engine block or head. Look for wear, scoring, pitting,or other deterioration.Lay the camshaft in oiled paper supports in vee blocks on a surface table.Assemble a dial test indicator (DTI) to a base and zero on centre journal.Rotate shaft and observe variation in needle position to indicate if theshaft is bent.Measure and record cam lift on all lobes. Compare with manufacturer’s data.Measure cam journals with external micrometer and record results. Measurefor ovality. Measure internal dimensions of bearings and record. Comparereadings with manufacturer’s data for size and wear tolerances.Reassemble shaft and other components. Run engine and listen for abnormalnoises.www.FreeEngineeringbooksPdf.com
The inspection of auxiliary shafts is a similar procedure.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 5: Remove and reinstall engine (RWD)without transmissionProcedureObtain crane, sling and lifting eyes with a SWL in excess of engine weight.Disconnect battery earth/ground cable. Fit lifting eyes to engine as permanufacturer’s instructions. Label and disconnect all electrical cables toengine including engine ground cable. Label and disconnect all vacuumpipes to engine. Remove air intake ducting and air cleaner, blank off openpipes.Depressurize, label and disconnect fuel lines to engine, blank off pipes. Labeland disconnect throttle/choke and other control cables. Disconnectexhaust down pipe at manifold flange. Remove, if necessary, the startermotor and clutch operating mechanism (cable or hydraulic). Slacken allclutch housing bolts and remove all but two, one either side. Slacken andremove, if safe to do so, the engine mounting nuts from the underside ofvehicle.When all underside work is completed, drain the coolant and remove radiatorand all hoses. When air conditioning is fitted, do not disconnectrefrigerant pipes/hoses before removing refrigerant (specialist task). Ifwww.FreeEngineeringbooksPdf.com
possible, remove and support the compressor with hoses attached.Attach sling to lifting eyes and crane, tension sling. Check all connections toengine have been disconnected. Remove engine mounting nuts/bolts if notalready removed. Operate crane to lift engine clear of mountings. Put ajack under the gearbox and lift slightly. Remove remaining clutch housingbolts. Pull engine forward away from the gearbox. Lift slowly and steadilymaking sure that the engine does not get caught in the compartment.Before replacing the engine, check the alignment of the clutch centre plateand spigot (pilot) bush or bearing in the crankshaft. Check the engine toclutch housing locating dowels are in place. Select first or second gear inthe gearbox. To replace, carefully lower the engine into the compartmentand push onto the gearbox. Keep the engine and gearbox square andcentralized. Rotate the engine crankshaft to align the clutch and gearboxinput shaft splines.Push the engine fully home onto the locating dowels and fit two bolts toclutch housing and tighten. Remove the jack from under the gearbox andlower engine into the mountings. Fit and tighten engine mountingnuts/bolts and remove crane and sling. Replace all components in reverseorder. Make a systematic check of all components for correct fitting andsecurity. Road test and recheck under bonnet.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 6: Remove and reinstall transverseengine and transmission (FWD) with craneProcedureObtain crane, sling and lifting eyes with a SWL in excess of engine weight.Disconnect battery earth/ground cable. Fit lifting eyes to engine as permanufacturer’s instructions.Label and disconnect all electrical cables to engine including engine groundcable. Label and disconnect all vacuum pipes to engine. Remove air intakeducting and air cleaner, blank off open pipes. Depressurize, label anddisconnect fuel lines to engine, blank off pipes. Label and disconnectthrottle/choke and other control cables. Disconnect exhaust down pipe atmanifold flange.Disconnect the gear change remote linkage at the gearbox. Remove thespeedo drive cable. Disconnect the clutch cable or hydraulic cylindercomplete with pipes. Remove the drive shafts from the final drive (catchoil). Fit dummy shafts to retain sun wheels. Slacken and remove, if safe todo so, the engine mounting nuts from the underside of vehicle.When all underside work is completed, drain the coolant and remove radiatorand all hoses. When air conditioning is fitted, do not disconnectwww.FreeEngineeringbooksPdf.com
refrigerant pipes/hoses before removing refrigerant (specialist task). Ifpossible, remove and support the compressor with hoses attached.Attach sling to lifting eyes and crane, tension sling. Check all connections toengine and gearbox have been disconnected. Remove engine mountingnuts/bolts if not already removed. Operate crane to lift engine clear ofmountings. Lift slowly and steadily making sure that the engine andgearbox do not get caught in the compartment.To replace, carefully lower the engine and gearbox into the compartment andlocate onto the engine mountings. Fit engine mounting nuts/bolts andtighten. Remove crane and sling. Refit drive shafts and check and top upgearbox oil. Replace all components in reverse order. Make a systematiccheck of all components for correct fitting and security. Start and runengine, bleed cooling system, if necessary, check for correct operation.Road test and recheck under bonnet.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 7: Remove and reinstall transverseengine and transmission onto trolley (includes frontframe and suspension, OBD1 or newer)ProcedurePlace vehicle on a suitable lift with the lifting points correctly positioned (seeworkshop manual). Obtain special or suitable trolley.Disconnect battery ground cable. Underneath the vehicle remove exhaustdown pipe, gear change linkage, speedo cable, clutch control cable orhydraulics, steering column coupling and brake connections (hoses orpipes). Blank off pipes.Under the bonnet label and disconnect electrical terminals, vacuumconnections, fuel feed and return pipes (plug or cap pipes), air ducting,throttle and other control cables. Drain coolant and remove radiator andhoses.When air conditioning is fitted, do not disconnect refrigerant pipes/hosesbefore removing refrigerant (specialist task). If possible, remove andsupport the compressor with hoses attached.Check all connections to the engine, transmission and sub frame have beenwww.FreeEngineeringbooksPdf.com
disconnected.Lower vehicle so that the sub frame rests on the trolley. Undo and removesub frame to chassis mounting bolts.Note: check that bolts are not supporting a load before removal.Carefully lift the vehicle away from the sub frame, watching that the engineand transmission does not catch in the engine compartment.Refit and reassemble in the reverse order. Tighten all nuts/bolts to specifiedtorque settings. Make a systematic check of all components for correctfitting and security.Bleed and check brakes. Check front wheel alignment. Run the engine, bleedcooling system, if necessary, and check for correct operation.Road test and recheck all work under the vehicle and under the bonnet.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 8: Inspect and replace sump, covers,gaskets and sealsProcedureDisconnect battery ground cable.Paper gaskets – remove cover/housing and clean old gasket material andsealant from both gasket faces. Check faces for flatness, rectify asnecessary. Fit new gasket with sealant, if specified, refit bolts and tightento specified torque.Rubber gaskets – remove cover/housing and clean old gasket material fromboth faces. Check gasket faces for flatness, rectify as necessary. Fit newgasket without sealant to clean and dry faces, refit bolts and tighten untilgasket is pinched. Do not over tighten.Cork gaskets – remove cover/sump and clean old gasket material and sealantfrom both gasket faces. Check faces for flatness, rectify as necessary. Fitnew gasket with sealant, if specified, refit bolts and tighten to specifiedtorque and in sequence.Formed in place gaskets (tube applied) – remove cover/sump and clean oldgasket sealant from both faces. Check faces for flatness, rectify asnecessary. Apply sealant bead gaskets as per manufacturer’s instructions.www.FreeEngineeringbooksPdf.com
Fit and torque in sequence within 3 minutes.Oil seals – these are used with gaskets for sealing around bearing caps and oilmoulded rubber pans. Fit with recommended sealants or dry and then fitother type of gaskets and sump. Fit and torque bolts in sequence. Checkseals do not squeeze out.Oil seals (lip) – remove pulley from housing and inspect seal land. Use aspecial tool to extract the seal. Press in new seal to shoulder or specifieddepth. Lubricate (in block) seal with clean engine oil. Clean and lubricateseal land, refit pulley and torque bolt.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 9: Remove and replace crankshaft,vibration damper, flywheel and clutch pilotbush/bearingProcedureRemove gearbox and clutch, strip underside of engine, sump and front coverto access crankshaft. Check and record the end float on the crankshaft.Undo front pulley/vibration damper bolt (lock flywheel to aid undoing ofbolt). Pull off pulley/damper and inspect seal land and pulley vee faces.Remove the front cover and timing belt or chain. Check and markdirection of rotation and timing. Remove bolts securing the flywheel/flexplate/drive plate and carefully remove flywheel taking weight in bothhands. Remove rear main oil seal housing. Inspect flywheel.Check the big end and main bearing caps for position (No. 1, 2, etc.) and slideto the front of engine. If not marked, mark with dots with a centre punchor similar. Remove big end bearing caps and lay out in order. Removemain bearing caps and lay out in order. Lift out crankshaft. If workingbelow vehicle, remove centre bearing and crankshaft together. Inspectcrankshaft for surface cracks and journal damage. Remove all bearingshells if they are to be replaced. Check oil passage condition. Measurejournal wear. Fit new bearings into connecting rods and main bearingswww.FreeEngineeringbooksPdf.com
caps, locate tangs and oil way holes. Check new bearings for ‘nip’ byassembling finger tight and checking cap gap with feeler gauge.Pull out clutch pilot bearing from crankshaft. If a bush, fill with grease andpunch in with a suitable mandrel to push out bush. Otherwise use specialpuller. Check new bearing fits gearbox input shaft and then fit intocrankshaft. There is no bush/bearing on some transaxles and autogearboxes.Fit new oil seals to front and rear housings or around crankshaft ifappropriate. Lubricate all bearings and journals with clean engine oil. Fitcrankshaft into main bearings in the block. Check end float. Fit mainbearing caps and tighten the bolts to the specified torque and check enginerotation. Fit big end bearing caps and tighten to torque and check enginerotation (fit timing chain). Fit front and rear main covers, centralize andtighten bolts in sequence and to torque. Fit flywheel/drive plate to dowelsand fit bolts, apply sealant or thread locking compound, if specified.Tighten bolts in sequence and to torque. Check run out. Fit timing beltand pulleys and covers. Fit pulley/vibration damper. Before fitting new oilfilter, prime the pump with clean engine oil through the oil feed hole tothe oil filter. Fit filter. Make a systematic check of all components forcorrect fitting and security. Fit gearbox, sump/sump and othercomponents. Fill engine with oil, start and run engine and check forcorrect operation.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 10: Inspect crankshaft condition, journaland bearing dimensions and wearProcedureStrip to access the crankshaft. Check end float and general condition beforeremoving. Check all bearing caps are marked for position and location tothe front of the engine.Remove crankshaft and bearings. Visually inspect bearings for condition,wear and abnormal markings.Visually inspect the crankshaft journals and thrust faces for scores, pittingand abnormal wear or uneven markings.Lay the crankshaft in oiled paper supports in vee blocks on a surface table.Set up a dial test indicator (DTI) on a base. Measure the crankshaft forbow (support ends – rotate and measure centre) and twist (comparematched pairs of journals, 1&4, 2&3, etc.).Measure and record all journal sizes for nominal size, taper and ovality.Compare with manufacturer’s data for wear tolerances.Check oil ways in the crankshaft are clear and clean. Flush through with lowpressure jet on cleaning tank.www.FreeEngineeringbooksPdf.com
If crankshaft is reground, wash thoroughly before refitting. Fit correctbearings (undersize if crankshaft has been reground). Check on journalsbefore fitting.Lubricate all bearings with clean engine oil. Check ‘nip’ of bearings beforetightening. Torque bearing cap bolts to specified torque and check enginerotates. Check ‘feel’ of bearings and end float of crankshaft beforereassembling engine.When the engine is running check for abnormal noises and correct operation.www.FreeEngineeringbooksPdf.com
Job cardAssessor reportwww.FreeEngineeringbooksPdf.com
Worksheet 11: Inspect pistons, piston rings andconnecting rods and bearingsProcedureRemove cylinder head and sump to access pistons and connecting rods.Before removing pistons check the condition of the piston crowns and the‘fit’ of the pistons in the cylinder bores. Rock the pistons from side to sideto ‘feel’ the free play.Visually inspect cylinder bores for scores, indicating broken piston rings, andfor uneven wear to one side, indicating misalignment or a bent connectingrod. Before removing the connecting rod big end bearing caps check forfree play by ‘feel’ by pulling and pushing the connecting rod on thecrankshaft journal. Check end float by side to side movement and feelergauge. Compare with manufacturer’s data.Remove connecting rods and pistons. Visually inspect the big end bearingsfor uneven wear indicating a possible bent connecting rod. Visuallyinspect the cylinder bore for matched wear. Visually inspect thecrankshaft journals and bearings. If the bearings are worn, measure thecrankshaft journals and compare with the manufacturer’s specificationsand tolerances for fitting new bearings without regrinding the crankshaft.www.FreeEngineeringbooksPdf.com
Clean the piston crown and inspect for burning or overheating damage,pitting, particle damage such as broken piston rings and otherdeterioration.Vi
automotive courses. Step-by-step guides to the practical tasks required for all Level 2 qualifications. Job sheets for students to complete and feedback sheets for assessors to complete. Tom Denton is the leading UK automotive author with a teaching career spanning lecturer to head of automotive engineering in a large college. His
automotive courses. Step-by-step guides to the practical tasks required for all Level 1 qualifications. Job sheets for students to complete and feedback sheets for assessors to complete. Tom Denton is the leading UK automotive author with a teaching career spanning lecturer to head of automotive engineering in a large college. His
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Medical Laboratory Technician and Laboratory Phlebotomy Technician Textbook List p. 48 Medical Laboratory Technician and Laboratory Phlebotomy Technician Course . appropriate patient care are integrated into each area of the curriculum. . Phlebotomy Technician programs promise t
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